Battery Module Bus Bar Layout With Fuse-Wire Cell Connections
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Solution Overview
Problem
Existing battery modules lack simplicity and modularity, requiring complex designs and increased size due to individual wire connections between battery cells and bus bars, which complicates thermal management and increases costs.
Innovation Solution
A battery module design featuring cylindrical battery cells with terminals connected via wires acting as fuse elements, ensuring equal ohmic resistance and simplified connections, using a single support structure and bus bars connected via wires for efficient thermal management and reduced size, with optional parallel circuit elements for increased capacity and hybrid series-parallel configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual wire connections are used between battery cells and bus bars, then each battery cell can be individually fused and connected with optimal ohmic resistance, but the device complexity and size increase
Solution Approach 1:
The patent divides the connection system into modular segments where each battery cell has its own dedicated wire connection to the bus bar. This segmentation allows individual fusible links for each cell while maintaining a systematic arrangement that reduces overall complexity. The support structure further segments the mounting locations, organizing the connections in a structured manner.
Solution Approach 2:
The patent transitions from a two-dimensional planar connection layout to a three-dimensional configuration by vertically arranging battery cells and routing wires through multiple levels. The support structure provides vertical mounting positions, and wires can route through the depth of the assembly, allowing connections without crossing or interfering with each other, thus reducing complexity.
2Reliability
If conventional individual wire connections are used for each battery cell, then reliable electrical connection is achieved, but space consumption and manufacturing costs increase
Solution Approach 1:
The patent merges multiple wire routing paths into a consolidated connection system where wires for adjacent battery cells are bundled and routed together. The bus bar design integrates multiple connection points in a compact arrangement, and the support structure combines mounting functions for both cells and electrical connections, reducing the overall volume required.
Solution Approach 2:
The support structure serves multiple functions simultaneously: it provides mechanical support for battery cells, establishes mounting locations for electrical connections, and organizes the spatial arrangement of wires. The bus bar acts as both an electrical conductor and a structural element that defines the connection geometry, reducing the need for separate components.
3Reliability
If complex connection structures are used between battery cells and bus bars, then reliable electrical connection is achieved, but thermal management becomes more difficult
Solution Approach 1:
The patent extracts the thermal management function from the electrical connection structure by providing dedicated thermal contact surfaces that are separate from the wire connection points. The support structure includes thermal management elements that directly contact battery cells, allowing heat dissipation without interfering with the electrical wiring arrangement.
Solution Approach 2:
The patent applies different local qualities to different regions of the battery module: electrical connections are optimized for low ohmic resistance with direct metal-to-metal contact, while thermal management regions provide large surface area contact for heat dissipation. The support structure differentiates between areas for electrical connection and areas for thermal contact, allowing each function to be optimized independently.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves a space- and cost-saving configuration with improved thermal management, allowing for flexible expansion and efficient assembly, while ensuring individual battery cell protection against overcurrent through fuse-like wire connections and flexible thermal management.
Implementation Method 1
the wires are designed in terms of material and cross-section to function as an electrical fuse element and, in the event of overcurrent, to disconnect each battery cell individually from the module assembly
Implementation Method 2
These wires can be connected to the battery cells, bus bars, sensors and the like, for example, by ultrasonic welding (also known as wirebonding), laser welding, resistance welding and similar common methods
Implementation Method 3
These wires can be connected to the battery cells, bus bars, sensors and the like, for example, by ultrasonic welding (also known as wirebonding), laser welding, resistance welding and similar common methods
Implementation Method 4
These wires can be connected to the battery cells, bus bars, sensors and the like, for example, by ultrasonic welding (also known as wirebonding), laser welding, resistance welding and similar common methods
Data Source
AI summary
A battery module includes at least one first battery cell and at least one second battery cell, a support structure, a first bus bar and a second bus bar. The first battery cell and the second battery cell are received in the support structure in the same orientation. The first bus bar and the second bus bar are disposed on said support structure. The first battery cell and the second battery cell each have a first terminal and a second terminal. Furthermore, batteries that can be manufactured from one type of disclosed battery module are also disclosed. The batteries can be manufactured, for example, by serial interconnection using the coupling sections and parallel interconnection using the parallel circuit elements.